US3908247A - Apparatus for conveying elongated material such as textile material - Google Patents

Abstract

Strands of yarn are dyed in a continuous process which includes: applying a dye to the yarn with a padder, printing a pattern on the yarn, fixing the dye with a steamer, washing the yarn, drying the yarn, heat-setting the yarn, cooling the yarn, coating the yarn, and finally taking the yarn up on a spool. The yarn is conveyed through stations performing these various processes by initially configuring parallel strands of the yarn into a plurality of warps which are then separated into two spaced arrays. An entraining strand of yarn is then woven between the arrays of warps as the arrays are raised and lowered relative to one another. As the entraining strand of yarn is woven through the arrays of warps, it is captured sequentially by a pair of parallel chains which carry the entraining strand and warps through the afore-mentioned processes. The entraining strand of yarn is formed in a continuous loop which is dispensed from a shuttle upstream of the padding process and is retrieved from the parallel chains downstream of the cooling process. After coating the yarns, they are taken up on a rotating spool which is driven by a continuous belt that engages the yarn as the yarn coils about the spindle of the spool. In this way, the yarn is conveyed through the various afore-mentioned processes while in a tensionless state.

Description

United States Patent 11 1 Murphy 1451 Sept. 30, 1975 1 APPARATUS FOR CONVEYING ELONGATED MATERIAL SUCH AS TEXTILE MATERIAL [75] Inventor: Lonnie A. Murphy, Chattanooga.

Tenn.

[73] Assignee: Wadsworth-Greenwood Corporation. Dalton. Ga.

[22] Filed: Oct. 25, 1973 [2]] Appl. No.: 409,465

[52] US.Cl 28/1 R: 28/40: 28/75 R:

34/162; 242/68 [51} Int. Cl.'- D06? 3/00 [58] Field ofSearch 28/1 R, 28, 30, 54, 55.

Prinmry liramincr-Mervin Stein .-1Imrne v. Agent. or FirmSherman & Shalloway [57] ABSTRACT Strands of yarn are dyed in a continuous process which includes: applying a dye to the yarn with a padder. printing a pattern on the yarn. fixing the dye with a steamer. washing the yarn. drying the yarn. heatsetting the yarn. cooling the yarn. coating the yarn, and finally taking the yarn up on a spool. The yarn is conveyed through Stations performing these various processes by initially configuring parallel strands of the yarn into a plurality of warps which are then separated into two spaced arrays. An entraining strand of yarn is then woven between the arrays of warps as the arrays are raised and lowered relative to one another. As the entraining strand of yarn is woven through the arrays of warps, it is captured sequentially by a pair of parallel chains which carry the entraining strand and warps through the afore-mentioned processes. The entraining strand of yarn is formed in a continuous loop which is dispensed from a shuttle upstream of the padding process and is retrieved from the parallel chains downstream of the cooling process. After coating the yarns. they are taken up on a rotating spool which is driven by a continuous belt that engages the yarn as the yarn coils about the spindle of the spool. In this Way. the yarn is conveyed through the various aforementioned proeesses while in a tensionless state.

24 Claims, 9 Drawing Figures US. Patent Sept. 30,1975 Sheet 2 of5 3,908,247

US. Patent Sept. 30,1975 Sheet 4 of5 3,908,247

US. Patent Sept. 30,1975 Sheet 5 of5 3,908,247

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APPARATUS FOR CONVEYING ELONGATED MATERIAL SUCH AS TEXTILE MATERIAL BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to methods of and apparatus for dyeing yarn in a continuous process. More particularly, the present invention relates to methods of and apparatus for dyeing a plurality of strands of yarn in a continuous process involving a plurality of steps.

2. Technical Considerations in Prior Art In the manufacture of textile materials, it is often necessary to dye strands of yarn which are subsequently woven into fabric composing the material. If the material happens to be used for carpets, especially tufted carpets, many problems are encountered in maintaining the quality of the yarn while achieving the desired color effect. Generally, these problems result from current practices in handling and conveying the yarn. Since it is necessary to process numerous strands of yarn simultaneously, in order to economically manufacture carpet, or for that matter, any other textile material, the methods of and apparatus for handling and conveying the material can become quite complex. As this complexity increases, it becomes more and more difficult to control the yarn being processed.

In order to produce high quality carpet, it is necessary that the tufts of yarn making up the carpet have certain qualities in order to give the carpet the desired feel of plushness. Each strand of yarn must therefor maintain its firmness or stiffness. In other words, each strand of yarn should retain a degree of elasticity or springiness. This quality of springiness is exemplified by not only a longitudinal stiffness, but by a bulkiness or a tendency for separate filaments in each strand of yarn to expand laterally against the confines of the twist. It is this stiffness and firmness-that prior art techniques tend to attack when handling or conveying strands of yarn.

The primary culprit which must be combatted to maintain firmness and stiffness of the individual yarn strand is tension which, in some prior art processes, is applied to the strands of yarn as the strands are pulled by their own strength through various processing stations. The general prior art approach to relieving tension on the strands is to simply lay the strands on a moving conveyor. This, of course, presents problems because, while the strands are being processed, they are subject to shrinking, stretching, fluid streams and the like, which tend to cause the strands of yarn to entangle or separate or, perhaps, become interwound with some of the processing machinery. When this happens, the process must be shut-down which, of course, results in economic losses.

In order to alleviate the afore-mentioned problems, which are essentially control problems, the carpet industry, among others, has resorted to a knit and de-knit process, wherein the individual strands of yarn are knitted into a sock before the yarn undergoes the dyeing process. By having the yarns knitted together, they control one another, so that the process is essentially working on increments of a relatively large mass as the yarn is dyed. By knitting the yarn into the afore-mentioned socks, some of the tension on the individual strands is reduced. However, the sock, at least along some portions or in some work stations of the process, must be pulled by its own strength in order to advance. This, of

course, tensions the individual strands. By tensioning the individual strands, some of the aforementioned firmness or stiffness is lost, especially if the strands are stressed beyond their elastic limit.

The socks present an additional problem in that as the individual strands are tensioned, they tend to squeeze together, forcing each filament of the strands into close engagement which is undesirable in that processing chemicals, such as dyestuffs, cannot penetrate between the fibers to dye the whole yarn. In this situation, after tension on the individual yarn strand is released and the fibers separate, the undyed portions become visible or show through which, of course, is not a desirable situation. Furthermore, in subsequent operations', such as steaming, washing or drying, the interior fibers may be shielded from fluid circulation which takes place during these processes. Consequently, these processes may not be complete or, if completed, they make take a longer time.

When the sock is deknitted, the yarn is full of kinks which are heat-set in the yarn due to the steaming and drying processes. These kinks prevent the yarn from standing erect after it is tufted into carpet- A rather obvious disadvantage of using the knit/deknit process is that the socks must be knitted prior to the dyeing process, and then deknitted subsequent to the dyeing process. This requires two expensive machines which must be inserted into the production line. Since one of these machines is a knitting machine, it will necessarily be rather complex and sensitive and, perhaps, will be subject to considerable down-time. This, of course, can shut down the entire dyeing process if not enough yarn sock has been knitted in reserve. If there is a reserve of yarn sock, it must, of course, be stored somewhere, which uses valuable space. Consequently. it is readily seen that disposal of the entire knit/deknit process would be quite desirable.

SUMMARY OF THE INVENTION In view of the afore-mentioned problems of the prior art, it is an object of the instant invention to provide a new and useful method of and apparatus for dyeing textiles.

It is another object of the instant invention to provide a new and useful method of and apparatus for dyeing textile materials, wherein strands of yarn used to fabricate the materials are subject to adequate control as the yarns undergo the dyeing process.

It is still another object of the instant invention to provide a new and improved method of and apparatus for dyeing textile materials, wherein the strands of yarn which are used to fabricate the materials are maintained in a substantially tensionless state as they undergo the dyeing process.

It is a further object of the instant invention to pro- .vide a new and improved method of and apparatus for dyeing textile materials, whereinfirmness and stiffness of individual yarns composing the fabric of the material is maintained.

It is still a further object of the instant invention to provide a new and improved method of and apparatus for dyeing textile materials, whereinentanglement of .dyeing textile materials, wherein dye penetration into individual yarns of the material to coat filaments composing the yarn is encouraged.

It is still another object of the instant invention to provide a new and improved method of and apparatus for conveying a plurality of yarns or the like through one or more processing stations.

It is still a further object of the instant invention to provide a method of and apparatus for taking strands of yarn up on a rotating drum or spool.

In accordance with these and other objects, the instant invention contemplates a process for conveying a plurality of strands of material longitudinally along the path by dividing the strands of material into separate arrays and interweaving a carrier strand between the arrays to entrain the strands of material with the carrier strand. As the carrier strand is interwoven with the arrays, the carrier strand itself is advanced. Tension is thus created in the carrier strand instead of in the individual strands of material, and the carrier strand acts as both a conveyor and a supporter.

In accordance with the afore-mentioned and other objects, apparatus for practicing the method of the instant invention contemplates conveying a plurality of webs along a planar path through a work station by using a guide means to divide the webs into two arrays, a displacement means for separating the two arrays, and shuttle means for interweaving a strand of material between the two arrays to entrain the two arrays. Apparatus for practicing the instant invention also includes transport means for capturing and advancing the entraining strand of material to thereby convey the webs along the path.

In addition, apparatus for practicing the method of the instant invention may include a take-up reel on which the strands of yarn are wound by passing the yarn between the spindle of the take-up reel and a moving belt, roller or the like against which the yarn rests as it is being taken up.

BRIEF DESCRIPTION OF THE DRAWINGS The present invention will become more fully understood from the following detailed description and accompanying drawings, in which:

FIG. 1 is a schematic illustration of apparatus for practicing the instant invention showing several processing stations which include an entraining station, a padding station, a printing station, a steaming station, a washing station, a drying station, a heat-setting station, a cooling station, a carrier strand removing station, a coating station, and a take-up station;

FIG. 2 is a top view of a conveyor mechanism, according to the instant invention, for conveying parallel webs or warps of textile material along a path through various processing stations of FIG. 1 by entraining the warps with an endless carrier strand;

FIG. 3 is a side view of the conveyor shown in FIG. 2 illustrating just how the warps are separated into a pair of arrays to receive the carrier strand, and are then directed back into substantially the same plane before passing through the various stations shown in FIG. 1;

FIG. 4 isan enlarged top view of a portion of FIG. 1 emphasizing that the carrier strand is disposed over one array of warps and under the other array of warps in an alternate fashion;

FIG. 5 is an end view of the arrangement of carrier strand and warps shown in FIG. 4;

port a plurality of spools that take the strands of yarn after the strands leave the coating station of FIG. 1;

FIG. 7 is a front view of the apparatus of FIG. 6 showing how a drive belt is positioned between flanges on the spools to engage the strands and cause the strands to wind around the spindles of the spools while holding the strands in firm engagement with the spindles;

FIG. 8 is a perspective view of the entraining station of FIG. 1 showing how a shuttle moves the carrier strand between the warps; and

FIG. 9 is a view similar to FIG. 8, showing how the shuttle moves the carrier strand around an advancing pin carried by a chain to effect transport of the webs.

DETAILED DESCRIPTION Referring now to FIG. 1, there is shown dyeing apparatus, designated generally by the numeral 21, which is used to practice the process of the instant invention. Thedyeing apparatus 21 is a work station which includes a plurality of schematically shown processes which are practiced on textile material, designated generally by the numeral 22, which moves along a path through the processes in the direction ofarrows 23. In accordance with the present invention,textile material 22 first passes through an entrainingstation 24 where the material is interwoven with a carrier strand, as will be fully explained hereinafter. The material 22 then passes sequentially through the following processing stations: a padding station 26, a squeezing station 27, aprinting station 28, a steamingstation 29, awashing station 31, a dryingstation 32, acooling station 33, a carrierstrand removal station 34, acoating station 35, and a take-up station 36.

The processes which occur at stations 26 through 32 and atstation 35 are generally conventional processes which are currently practiced in the dyeing of yarn for use in articles such as tufted carpets and the like. However, by utilizing theapparatus 21, thematerial 22 traverses the afore-mentioned stations in a substantially tensionless state, while thematerial 22 is advanced in the form of a plurality of parallel strands.

Referring now to FIG. 2, there is shown a conveying apparatus, generally designated by the numeral 41, which is used to advance the material 22 through the afore-mentioned processing stations, numbered 26 through 33. In accordance with the present invention, thematerial 22 is advanced from a storage creel or the like (not shown) separated into warps, generally designated by thenumerals 42a and 42b. As best seen in FIGS. 4 and 5, each warp consists of a plurality ofyarn strands 43. In the manufacture of some tufted carpet, thestrands 43 are preferably two-ply, arranged in a false twist, and about 2600 denier. A filament count of 2600 denier means that each strand will have 1800 to 2600 separate filaments.

Referring again to FIG. 2, in conjunction with FIG. 3, the warps of 42a and 42b pass between a pair of aligningrollers 44 and 45 which retain the warps in the same plane. To accomplish this, theroller 45 may simply rest on theroller 44, with thewarps 42a and 42b disposed therebetween. A means for accomplishing this is perhaps best seen in FIGS. 8 and 9, wherein theroller 63 is rigidly held in position, and thesimilar roller 62 is journalled to a pair ofarms 46 which are pivoted to rotate about anaxle 50.

After thewarps 42a and 42b emerge from between therollers 44 and 45, thewarps 42a are displaced in one direction and thewarps 42b are displaced in the opposite direction to create agap 47 therebetween. This gap is shown in FIGS. 1, 3, 8 and 9, and is effected by passing theweb 42a through a first array of apertures 4848 in a first array of guides 4949 and by passing thewebs 42b through a second array of apertures 5151 in a second array of guides 5252. As shown in FIG. 3, the guides 4949 are in a lowered po sition, while the guides 5252 are in a raised position. However, these positions may be reversed so that the apertures 4848 and guides 4949 are raised, while the apertures 5151 and guides 5252 are lowered, so that thewebs 42a are above thewebs 42b, as shown in FIGS. 8 and 9. In other words, thewebs 42a and 42b have a first mode, which is shown in FIG. 3, and a second mode, which is shown in FIGS. 8 and 9.

As seen in FIG. 3, thewarps 42a and 42b may be switched back and forth between the two aforementioned modes by a rack and pinion type device, designated generally by the numeral 53. The rack andpinion 53 is operated by a reciprocatingrod 54 which has arack section 55 thereon that engages agear 56 rigidly secured to a pinion 57. Therod 54 is preferably pneumatically actuated, but it may, of course, by operated by a magnetic solenoid or by mechanical means. As the pinion 57 oscillates in the directions of the double-headedarrow 58, arack 59 reciprocates the guides 4949 up and down, raising and lowering thewarps 42a, while arack 61 reciprocates the guides 5252 up and down to raise and lower thewarps 42b. Since theracks 59 and 61 are coupled by the pinion 57, the racks will move in opposite directions as the pinion 57 oscillates, shifting thewarps 42a and 42b up and down to assume alternately the first and second modes. While a rack andpinion arrangement 53 has been shown in the illustrated embodiment and, perhaps, is preferred because of its relative quietness, a pneumatic system or electrical system may, of course, also be used to raise and lower thewarps 42a and 42b.

After thewarps 42a and 42b pass through their respective apertures 4848 and 51-5 1, they are passed between a second set ofrollers 62 and 63, which again align the warps to advance in the same or substantially the same plane.

Before thewarps 42a and 42b pass between therollers 62 and 63, acarrier strand 65 is passed through thegap 47 in a direction transverse of the longitudinal path of the warps. Thecarrier strand 65 is dispensed from ashuttle 66 which is in the form of a hollow tube through the bore of which the carrier strand passes. Theshuttle 66 is reciprocated back and forth in the direction of the double-headedarrow 67 to dispense thecarrier strand 65 between thegap 47. Reciprocal motion may be imparted toshuttle 66 by any type of mechanical, pneumatic or electrical means suitable. In the illustrated embodiment, however,shuttle 66 is reciprocated by apneumatic cylinder 68 into opposite ends of which air is injected and exhausted in a conventional manner to reciprocate theshuttle 66. In operation, theshuttle 66 must proceed from one side of thewarps 42a and 42b to the other side of the warps, and then return to its initial position before the rack andpinion 53 moves the warps to reverse their mode. A conventional controller (not shown) is used to coordinate the operation of thepneumatic cylinder 68 with the reciprocation ofrod 54, which controls the operation of the rack andpinion 53.

When thewarps 42a and 4217 are in the first mode, in other words, the mode shown in FIG. 3, theshuttle 66 will dispense thecarrier strand 65 over thewarps 42a and under thewarps 42b. Prior to traversing across the path of travel assumed by thewarps 42a and 42b, thecarrier strand 65 is intercepted by one of a plurality ofpins 71 which project fromtabs 72 carried by achain 73. Thechain 73 is trained around a pair ofsprockets 76 and 77 positioned on one side of the path travel of the warps through thedyeing apparatus 21 and disposed at the entrainingstation 24 and the carrierstrand removal station 34.

For purposes of simplification in FIG. 2, only the upstream and downstream ends of thechain 73 are shown, the rest being broken away. However, it is to be understood that thechain 73 is supported in a conventional manner with a suitable array of idler sprockets. The chain moves in the direction of thearrow 74 and may be driven by any suitable means (not shown). As thechain 73 moves, it advances thepins 71 and, thus,

the portions of thecarrier strand 65 which the pins intercept. Consequently, as thecarrier strand 65 moves in the direction of thearrow 74 and as the carrier strand is displaced normally across the path of travel of thewebs 42a and 42b, the carrier strand will assume an angular orientation with respect to the webs and the direction represented by thearrow 74.

After theshuttle 66 transports thecarrier strand 65 completely across thewarps 42a and 42b, the shuttle deposits the carrier strand in the path of travel of one of another array ofpins 81 carried bytabs 82 projecting from asecond chain 83. Thechain 83 also moves in thedirection 74 in parallel relationship with thechain 73. Since thestrand 65 is in the path of travel of one of thepins 81, it will be intercepted by one of thepins 81 and carried by the pin in the direction of thearrow 74. After the strand is captured by thepin 81, thepneumatic actuator 68 withdraws theshuttle 66 and pulls thestrand 65 back through thegap 47 to its initial position to complete one cycle of the entraining or interweaving step. In order to facilitate looping thecarrier strand 65 about thepins 71 and 81, theshuttle 66 has a downwardly extendingportion 85 extending therefrom so that the pins may pass under theshuttle 66 without interference.

After a cycle is completed, the rack andpinion 53 changes the mode of thewarps 42a and 42b so that thewarps 42a are raised and thewarps 42b are lowered. After this happens, thecarrier strand 65 is pressed into interwoven relationship with thewarps 42a and 42b by therollers 62 and 63 so that the warps move generally in the same plane, as shown in FIG. 5. Since thecarrier strand 65 is moving in the direction of thearrow 74, thewarps 42a and 4212, which are now entrained in the carrier strand, will also move in the direction of thearrow 74, thereby being carried through thedyeing apparatus 21.

The segment shown in FIG. 4 illustrates how thecarrier strand 65 supports thewarps 42b, which rest on top of the carrier strand. Thewarps 42a, however, are beneath the carrier strand and, consequently, are not supported thereby. It is therefor necessary to, on the next cycle, weave thecarrier strand 65 beneath thewarps 42a and above the warps 4212. When thewarps 42a and 42b are switched from the first to the second mode, the

warps 42a are raised and thewarps 42b are lowered. Consequently, when theshuttle 66 dispenses thecarrier strand 65 in thegap 47, the carrier strand will be above thewebs 42a and below thewebs 42b, resulting inwebs 42a being supported. Accordingly, thestrand 65 will supply support for thewebs 42b during one cycle, and during the subsequent cycle, will supply support for thewebs 42a, thereby providing all of the webs with sufficient support as the web advance through the various stations shown in FIG. 1.

In addition to supplying support for the alternate arrays ofwebs 42a and 42b, thecarrier strand 65 prevents the webs orindividual strands 43 composing the webs, from displacing upwardly into tangled engagement with mechanisms associated with various stations 26 through 33. Thestrand 65 therefor restrains thewebs 42a and 42b to motion along a parallel path through the stations of thedyeing apparatus 21. If any of thestrands 43 composing thewebs 42a and 42b for some reason happen to break, the broken strands will be supported by thecarrier strand 65 and thereby prevent the broken strand from becoming entangled in the processing stations and possibly shutting down the dyeing operation. It can be readily seen that thecarrier strand 65 is the only strand under tension, whilestrands 43 composing thewarps 42a and 42b simply rest on the carrier strand and are held in a substantially tensionless state.

Referring now to mainly FIGS. 2 and 3, thecarrier strand 65 is removed from entrainment with thewarps 42a and 42b at thestrand removal station 34. The

strand removal station 34 includes first and second reciprocating guides 8686 and 8787, respectively, which have apertures 88-88 and 8989, respectively, through which thewarps 42a and 42b, respectively, pass. The guides 8686 and 8787 are substantially identical to the upstream guides 4949 and 52-52, and may be operated by a rack and pinion arrangement (not shown) which is substantially similar to the rack andpinion arrangement 53. As the guides 86-86 and 8787 reciprocate relative to one another, they displace thewarps 42a and 42b relative to one another to create agap 91 therebetween. Just as the first and second modes are created by the downstream guides 86--86 and 8787 as the downstream guides reciprocate, the upstream guides 49-49 and 5252 form thegap 91 by assuming first and second modes. In the first mode, theweb 42a is raised relative to theweb 42b so that theweb 42a is high and te web 42 is low, and in the second mode, theweb 42b is raised relative to theweb 42a so that theweb 42b is higher or above theweb 42a.

Thewarps 42a and 42b are restrained to move in the same plane, both upstream from and downstream from the guides 8686 and 8787 byupstream rollers 92 and 93 anddownstream rollers 94 and 95 between which the warps pass.

In the illustrated preferred embodiment, as best seen in FIG. 2, thecarrier strand 65 is endless. In other words, the carrier strand forms a loop as it is dispensed from the entrainingstation 24, is removed from entrainment withwarps 42a and 421; at theremoval station 34, and is then returned to the dispensingstation 24. Since thechains 73 and 83 continually advance the strand, the carrier strand is pulled from entrainment with thewarps 42a and 4312 at the removal station by tension applied to the strand as thepins 71 and 81 engage the strand at the entrainingstation 24.

Thestrand removal station 34 is positioned adjacent to and just downstream of thedownstream sprockets 77 and 77 while thecarrier strand 65 is passed through astationary tube 96 positioned just downstream of and just above thesprockets 77. Consequently, as thepins 71 and 81 move downwardly while going around thesprockets 77 and 77, thecarrier strand 65 is pulled from engagement with the pins. As clearly seen in FIG. 2, thepins 71 and 81 are staggered relative to one another, giving the carrier strand 65 a zig-zag configuration. Since thepins 71 and 81 are staggered relative to one another, the protion of thestrand 65 which has been pulled from engagement with thepin 81 has a chance to be completely drawn through theremoval tube 96 just before thepin 71 has moved adjacent to the end of thetube 96 and starts on its downward motion around thesprocket 77 to release the carrier strand to the tube. By utilizing this staggered arrangement of thepins 71 and 81, entanglement of thecarrier strand 65 is prevented.

As best seen in FIG. 1, thetextile material 22, which in the preferred embodiment is composed of thewarps 42a and 42b, undergoes three passes in the steamingstation 29. This is done to prolong exposure of the material 22 to the steaming process and is accomplished by simply training thechains 73 and 83 about thesprockets 101 and 102 positioned in the steaming station. While three passes through the steaming station are shown,'it is to be understood that more passes may be utilized if it is desired to further increase exposure of thetextile material 22 to the steamingprocess 29. As thechains 73 and 83 move between thesprockets 101 and 102, thematerial 22 is turned upside down and thepins 71 and 81 project downwardly instead of upwardly. Consequently, gravity will tend to cause thecarrier strand 65 to drop from thepins 71 and 81. In order to prevent this, two bars 103103 (only one of which is shown) extend in the steamingstation 29 parallel to the path of travel of thematerial 22. One of thebars 103 is positioned in the space between thepins 71 and the edge of the material 22 while the other bar is positioned between thepins 81 and the other edge of the material. If thecarrier strand 65 tends to fall from thepins 71 and 81, it will rest on thebars 103 and thereby be held in engagement with the pins.

Referring still to FIG. 1, it is seen that after thetextile material 22, composed of thewarps 42a and 42b, leaves the carrierstrand removal station 34, the material passes through thecoating station 35, in which a coating roller 104 deposits acoating 105 from adish 106 onto the textile material. It is necessary before thecoating process 35 to remove thecarrier strand 65 from entrainment with thewarps 42a and 42b to prevent small gaps in the coating from occurring on theindividual strands 43 at the areas where the carrier strand engaged the individual strands.

As thetextile material 22 leaves thecoating station 35, it proceeds to a take-up station 36 where it is wound on take-up spools, designated generally by the numeral 108. Referring now to FIGS. 6 and 7, where the take-up station 36 is shown in detail, a plurality of the take-upspool 108 are arranged on arack 109. Eachspool 108 takes up a single strand 43 (see FIGS. 4 and 5) so that there must be one spool for each strand of yarn. In other words, if there are two hundredstrands 43 of yarn, there must be two hundredspools 108.

As seen in FIG. 6, spools 108 are disposed at an angle of about with the vertical, and rest against an endless drive belt 111 positioned adjacent to thespindles 112 of the spools. Eachspool 108 has a pair ofcircular flanges 113 positioned at the ends of thespindle 112. As seen in FIG. 7, the endless belt 111 is disposed between theflanges 113. Consequently, when thematerial 22 is inserted between the belt 111 and one of thespindles 112, the material will wind about the spindles as the belt advances in the direction ofarrow 114.

As best seen in FIG. 6, theflange 113 above each of thespools 108 rest on braces ofroller 116. Each brace ofrollers 116 includes a plurality ofrollers 117, and is inclined at an angle with respect to the horizontal so that, as thetextile material 22 accumulates around thespindle 112, the take-upspool 108 advances in a direction of thearrow 118 away from the drive belt 111. As thematerial 22 accumulates, theflanges 113 move in the direction of thearrow 118 to rotate on sequential ones of therollers 117. Thebraces 116 ofrollers 117 are inclined slightly to the horizontal in order to cause thespools 108 to roll back into engagement with the belt 111 and rest thereagainst by the force of gravity. In FIG. 6, the right-hand spools 108 are shown receiving thematerial 22.

It should be noted that as thetextile material 22 moves between the carrierstrand removal station 34 and the take-upspool 108, very little tension will be applied to theindividual strands 43 because, as the material is taken up on thespools 108, it is being conveyed out of the carrier strand removal station. Accordingly, the only tension applied to each individual strand ofyarn 43 is enough tension to keep the material supported against the force of gravity. Even this tension may be deleted by utilizing some type of support, other than thecoating station 35 between the carrier strand removal station and the take-up station 36. Consequently, thetextile material 22 need not be pulled by its own strength between the carrierstrand removal station 34 and thespools 108 of thetakeup station 36. In addition, it should be noted that, at this point, thematerial 22 is already dyed and has been dryed and cooled in thestation 32. Therefore, any tension or stress on theindividual strands 43 of the material is not as critical as tension and stress would be if applied during the dyeing process when the textile material is hot and wet.

By way of example, eachspool 108 may hold an 8 hour supply ofmaterial 22 or yarn in the form of asingle strand 43. Generally, thestrands 43 advance at 100 ft/min. through theapparatus 21 and eachspool 108 accumulates 60,000 feet of yarn. Since 3,000 feet of yarn weighs one pound, approximately pounds of yarn is wound on eachspool 108. After thespools 108 are full, the yarn thereon is transferred to bobbin packages (not shown) which weigh three to five pounds for subsequent sale or use.

Thecarrier strand 65 may be made of yarn perhaps, perphas, glass fiber. It is only necessary that the carrier strand be strong enough to support thewarps 42a and 4212 as the warps are advanced through the various processes in thedyeing station 21 and that the carrier strand be strong enough to withstand numerous bends the changes in environment without succumbing to fatigue. The material composing thestrand 65 should not interact with thetextile material 22 or with the dyestuffs dispensed at station 26 and the steam dispensed atstation 29. In choosing a material for thecarrier strand 65, it should be remembered that substantially all of the tension applied in theconveyingsystem 41 is assumed by the carrier strand. In view of these considerations, it is believed that a glassfiber carrier strand 65 will give good service.

While the methods and apparatus of the instant invention have been illustrated by way of the foregoing drawings and embodiments, which are for purposes of illustration only, the methods of the instant invention and the apparatus for practicing the instant invention are limited only by way of the following appended claims.

What is claimed is: 1. An apparatus for conveying a plurality of webs along a planar path through a work station, comprising: guide means for dividing the webs into at least two arrays;

displacement means for separating the guide means to displace the two arrays laterally out of the plane of the path;

shuttle means for carrying a strand of material between the two arrays and across the path when the arrays are displaced;

intercepting means for capturing the strand of material on each side of the path;

transport means for moving the intercepting means parallel to the path so that the captured strand moves parallel to the path; and

activating means for reversing the displacement of the arrays to move the webs in opposite directions through the planer path after the intercepting means has captured the strand of material to thereby entrain the webs with the strand and cause the transport means to convey the webs along the path.

2. An apparatus according to claim 1, wherein the guide means includes a series of apertures, each of which engages a separate web and alternate ones of which form an array.

3. An apparatus according to claim 2, wherein the displacement means includes a pinion which reciprocates two racks relative to one another, wherein one rack displaces the apertures of one array and the other rack displaces the apertures of the other array.

4. An apparatus according to claim 1, wherein the shuttle means includes a tube having a bore therethrough through which the strand passesand from which the strand is dispensed as the shuttle moves between the arrays.

5. An apparatus according to claim 1, wherein the transport means includes a pair of parallel chains which advance parallel to the planer path and wherein the intercepting means includes a plurality of projections spaced along said chains around which the strand is carried to capture the strand.

6. An apparatus according to claim 5, wherein the projections on one chain lead the projections on the other chain so that the projections on opposite chains are staggered in relation to one another and so that the strand follows a zig-zag path in relation to the planer path.

7. The apparatus of claim 1, further including means to take-up the webs after the webs pass through the work station, wherein the take-up means comprises:

a spool having a spindle for winding the webs thereon and a pair of circular flanges for retaining the webs on the spindle as the webs are wound;

bearing means for supporting the spool by rotatably engaging said flanges; and

drive means for rotating the spool to take-up the webs by frictionally engaging the webs to wind the webs about the spindle.

8. The apparatus of claim 7, wherein the drive means includes a moving belt which fits between the flanges of said spool to engage the webs and hold the webs in wound engagement with the spindle.

9. The apparatus of claim 8, wherein the bearing means is inclined with respect to the horizontal to cause the webs winding on the spool to bear against the belt.

10. The apparatus of claim 9, wherein the bearing means comprises a plurality of rollers mounted on an inclined support and along which the flanges progress as the webs are taken up and the spindle displaces away from the belt.

11. An apparatus for dyeing textile yarns, wherein the yarns are advanced along a path through a work station having a plurality of processes which are arranged in tandem and which include: padding, printing, steaming, washing, drying, heat-setting, cooling, and coating, wherein the improvement is characterized by:

a carrier strand for conveying the yarns along the path;

means for interweaving the carrier strand between the yarns to entrain the yarns therein upstream of the work station;

means for capturing the carrier strand to support the carrier strand on opposite sides of the path assumed by the yarns; and

means for advancing the capturing means to move the carrier strand along the path through the work station to thereby convey the yarns through the work station, said advancing means being laterally spaced from the path of said yarns.

12. The apparatus of claim 11, further including:

means for removing the carrier strand from between the entrained yarns downstream of the work station.

13. The apparatus of claim 12, wherein the carrier strand is a continuous loop which returns from downstream of the work station to upstream of the work station to continuously entrain and convey the yarns.

14. The apparatus of claim 1 1, wherein the means for advancing the carrier strand includes a pair of endless conveyors disposed on opposite sides of the path.

15. The apparatus of claim 14, wherein the means for capturing the carrier strand include projections which extend from the endless conveyors around which the carrier strand is looped.

16. The apparatus of claim 15, further including means positioned in the work station for reversing temporarily the direction of advance of the yarns during the steaming process to prolong exposure of the yarns to the steaming process.

17. The apparatus of claim 16, wherein the reversing means includes:

means for reversing the direction of the endless conveyors; and

retaining means extending in the work station for engaging the carrier strand to hold the carrier strand around the projections upon reversing the direction of the endless conveyors.

18. An apparatus for conveying a plurality of yarns along a path, comprising:

a carrier strand for conveying the yarns along the path;

means for interweaving the carrier strand with the yarns to entrain the yarns therein at an upstream station;

means for capturing the carrier strand to support the carrier strand on opposite sides of the path assumed by the yarns; and

means laterally spaced from said path for advancing the capturing means to move the carrier strand over the path to thereby convey the plurality of yarns.

19. The apparatus of claim 18, wherein the carrier strand supports the yarns against forces normal to the path after the carrier strand is captured by the capturing means.

20. The apparatus of claim 18, further including:

means for removing the carrier strand from between the entrained yarns after the yarns have been conveyed by the carrier strand.

21. The apparatus of claim 20, wherein the carrier strand is a continuous loop which is returned from the removing means to the interweaving means as the yarns are conveyed.

22. The apparatus of claim 18, wherein the means for advancing the capturing means including a pair of endless conveyors upon which the capturing means are mounted-and which are disposed to advance on opposite sides of the path and wherein the interweaving means distributes the carrier strand alternately between the capturing means on each conveyor.

23. The apparatus ofclaim 22, wherein the means for capturing the carrier strand include projections which extend from the endless conveyors and around which the carrier strand is looped.

24. The apparatus ofclaim 22, wherein the capturing means on one conveyor is staggered with respect to the capturing means on the other, so that the capturing means in the act of capturing the carrier strand is downstream of the capturing means on the other conveyor which is to subsequently capture the carrier strand.

Claims (24)

1. An apparatus for conveying a plurality of webs along a planar path through a work station, comprising: guide means for dividing the webs into at least two arrays; displacement means for separating the guide means to displace the two arrays laterally out of the plane of the path; shuttle means for carrying a strand of material between the two arrays and across the path when the arrays are displaced; intercepting means for capturing the strand of material on each side of the path; transport means for moving the intercepting means parallel to the path so that the captured strand moves parallel to the path; and activating means for reversing the displacement of the arrays to move the webs in opposite directions through the planer path after the intercepting means has captured the strand of material to thereby entrain the webs with the strand and cause the transport means to convey the webs along the path.

2. An apparatus according to claim 1, wherein the guide means includes a series of apertures, each of which engages a separate web and alternate ones of which form an array.

3. An apparatus according to claim 2, wherein the displacement means includes a pinion which reciprocates two racks relative to one another, wherein one rack displaces the apertures of one array and the other rack displaces the apertures of the other array.

4. An apparatus according to claim 1, wherein the shuttle means includes a tube having a bore therethrough through which the strand passes and from which the strAnd is dispensed as the shuttle moves between the arrays.

5. An apparatus according to claim 1, wherein the transport means includes a pair of parallel chains which advance parallel to the planer path and wherein the intercepting means includes a plurality of projections spaced along said chains around which the strand is carried to capture the strand.

6. An apparatus according to claim 5, wherein the projections on one chain lead the projections on the other chain so that the projections on opposite chains are staggered in relation to one another and so that the strand follows a zig-zag path in relation to the planer path.

7. The apparatus of claim 1, further including means to take-up the webs after the webs pass through the work station, wherein the take-up means comprises: a spool having a spindle for winding the webs thereon and a pair of circular flanges for retaining the webs on the spindle as the webs are wound; bearing means for supporting the spool by rotatably engaging said flanges; and drive means for rotating the spool to take-up the webs by frictionally engaging the webs to wind the webs about the spindle.

8. The apparatus of claim 7, wherein the drive means includes a moving belt which fits between the flanges of said spool to engage the webs and hold the webs in wound engagement with the spindle.

9. The apparatus of claim 8, wherein the bearing means is inclined with respect to the horizontal to cause the webs winding on the spool to bear against the belt.

10. The apparatus of claim 9, wherein the bearing means comprises a plurality of rollers mounted on an inclined support and along which the flanges progress as the webs are taken up and the spindle displaces away from the belt.

11. An apparatus for dyeing textile yarns, wherein the yarns are advanced along a path through a work station having a plurality of processes which are arranged in tandem and which include: padding, printing, steaming, washing, drying, heat-setting, cooling, and coating, wherein the improvement is characterized by: a carrier strand for conveying the yarns along the path; means for interweaving the carrier strand between the yarns to entrain the yarns therein upstream of the work station; means for capturing the carrier strand to support the carrier strand on opposite sides of the path assumed by the yarns; and means for advancing the capturing means to move the carrier strand along the path through the work station to thereby convey the yarns through the work station, said advancing means being laterally spaced from the path of said yarns.

12. The apparatus of claim 11, further including: means for removing the carrier strand from between the entrained yarns downstream of the work station.

13. The apparatus of claim 12, wherein the carrier strand is a continuous loop which returns from downstream of the work station to upstream of the work station to continuously entrain and convey the yarns.

14. The apparatus of claim 11, wherein the means for advancing the carrier strand includes a pair of endless conveyors disposed on opposite sides of the path.

15. The apparatus of claim 14, wherein the means for capturing the carrier strand include projections which extend from the endless conveyors around which the carrier strand is looped.

16. The apparatus of claim 15, further including means positioned in the work station for reversing temporarily the direction of advance of the yarns during the steaming process to prolong exposure of the yarns to the steaming process.

17. The apparatus of claim 16, wherein the reversing means includes: means for reversing the direction of the endless conveyors; and retaining means extending in the work station for engaging the carrier strand to hold the carrier strand around the projections upon reversing the direction of the endless conveyors.

18. An apparatus for conveying a plurality of yarns along a path, comprising: a carrier strand for conveying the yarns along the path; means for interweaving the carrier strand with the yarns to entrain the yarns therein at an upstream station; means for capturing the carrier strand to support the carrier strand on opposite sides of the path assumed by the yarns; and means laterally spaced from said path for advancing the capturing means to move the carrier strand over the path to thereby convey the plurality of yarns.

19. The apparatus of claim 18, wherein the carrier strand supports the yarns against forces normal to the path after the carrier strand is captured by the capturing means.

20. The apparatus of claim 18, further including: means for removing the carrier strand from between the entrained yarns after the yarns have been conveyed by the carrier strand.

21. The apparatus of claim 20, wherein the carrier strand is a continuous loop which is returned from the removing means to the interweaving means as the yarns are conveyed.

22. The apparatus of claim 18, wherein the means for advancing the capturing means including a pair of endless conveyors upon which the capturing means are mounted and which are disposed to advance on opposite sides of the path and wherein the interweaving means distributes the carrier strand alternately between the capturing means on each conveyor.

23. The apparatus of claim 22, wherein the means for capturing the carrier strand include projections which extend from the endless conveyors and around which the carrier strand is looped.

24. The apparatus of claim 22, wherein the capturing means on one conveyor is staggered with respect to the capturing means on the other, so that the capturing means in the act of capturing the carrier strand is downstream of the capturing means on the other conveyor which is to subsequently capture the carrier strand.

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